DE102020007892A1 - Foamed, elastic, protein-based product, method for producing such products, in particular extruded meat analogues based on plant proteins and plant fibers, device for carrying out such a method and use of the product for producing meat analogues based on plant proteins - Google Patents

Abstract

The invention relates to a product with a foam structure with a set ratio of open to closed gas pores towards the product surface. Furthermore, the invention relates to a method with four embodiment variants according to the invention for the defined mechanical opening of closed foam pores. The invention also relates to a device with four design variants according to the invention for the defined mechanical opening of closed foam pores. Furthermore, the invention relates to the use of products designed according to the invention as meat analogs or plant protein-based textured, multi-phase foods, in particular vegetable or fruit composites. Particular advantages of the invention relate to the targeted influencing of the deformation and texture properties of foamed products and their accessibility from the outside for easy and quick filling of the open pores with fluid systems, which introduce additional functionalities into the product.

Description

The invention relates to a foamed, elastic, protein-based product.

Furthermore, the invention relates to a method for producing such a product with a defined degree of pore opening.

The invention also relates to a device for carrying out the method according to the invention.

Finally, the invention relates to the use of the product according to the invention as the main component for producing meat analogs based on plant proteins.

State of the art

Viscous masses can be foamed in extruders, in which gas is metered in under atmospheric or excess pressure, mixed/dispersed and/or partially or completely dissolved under excess pressure, is then released again by pressure relief and remains partially or completely incorporated in the viscous mass to form a foam /1 ,2/.

Another known possibility is the addition of foaming agents, which form a gas as a result of a chemical/physicochemical and/or thermal reaction, which is also partly or completely incorporated into the viscous mass with the aid of mixing/dispersing processes to form a foam. Corresponding viscous masses can be of a synthetic and/or biological nature or also consist of mixtures of such and can be the basis or component of products in the food, cosmetics, pharmaceuticals, building materials or plastics industries. In extruders, viscous masses foamed in this way are conveyed by the extruder screws and pressed through an extruder die. As a result of the narrowing of the flow cross section at the transition from the extruder housing to the extruder nozzle, a static pressure build-up takes place, which in the nozzle is reduced again to atmospheric pressure at the extruder nozzle outlet with the nozzle cross section being kept more or less constant via the flow shear stresses prevailing there as a result of wall friction and internal fluid friction. The pressure build-up in the die inlet zone (before entry into the die) compresses the gas trapped in the foam bubbles and thus reduces the size of the foam bubbles, the pressure reduction in the extruder die down to the outlet atmospheric pressure allows the gas in the foam bubbles to expand again and thus enlarges the foam bubbles. Larger gas bubbles can be deformed in the nozzle flow compared to smaller gas bubbles at lower flow stresses and, if a critical stress is exceeded, they can be broken up and thus converted into smaller bubbles.

As a rule, the aim is for a material strand with a defined shape to emerge from the extruder nozzle, since the product is also typically shaped by means of the extruder nozzle. The dimensional accuracy of such products is often also an important quality measure. This is achieved, among other things, by realizing a uniform laminar flow in the nozzle, which corresponds to a planar layered flow. If a foamed fluid system is moved in such a nozzle flow, there is increased shearing of the fluid system at the nozzle wall as a result of the typical parabolic flow profile, whereas no shearing occurs in the middle of the nozzle channel. Cross-mixing of the fluid system flowing in this way does not occur (parallel layered flow) provided the nozzle channel does not have any flow obstacles. The maximum wall shear rate present in the fluid layer in contact with the wall (= speed of the fluid film close to the wall under consideration on its side facing the center of the nozzle channel divided by the fluid film thickness) usually causes the formation of a boundary layer close to the wall. If the fluid system contains disperse components, these are set in rotation as a result of the wall shear rate effective in the fluid layer close to the wall under consideration and experience a dynamic buoyancy force (lift force), which causes the disperse components to separate away from the wall in the middle of the nozzle channel. This applies in principle to solid particles /3/ but also to gas bubbles 141 and leads to a depletion of the fluid layer close to the wall of such disperse components.

For the extrusion of meat analogues based on plant proteins, the “High Moisture Extrusion Cooking (HMEC)” process is preferably used. This stands for extrusion at high temperatures (up to approx. 170° C.) and high static pressures (up to approx. 100 bar) with product water contents of up to approx. 70% by weight. In an aqueous protein melt generated under these conditions, protein denaturation takes place in the form of protein fibrils that form, which in the extruder nozzle inlet flow in Oriented in the direction of flow as a result of elongational flow components that are effective there and solidified in this oriented structural state by subsequent cooling (to approx. 60° C.) in a long (≥ approx. 1 m) extruder cooling nozzle. In the case of typically laminar nozzle flow, the cooled product exits the extruder nozzle as a smooth strand. The oriented protein fibrils give the product a meaty, fibrous texture /5/. As a result of the slow cooling of the product in the extruder die, a sudden release of water vapor is suppressed and structure formation is therefore not disturbed.

The state of the art with regard to HMEC extrusion processes for the production of vegetable protein-based meat analogues is described, for example, in the patent specifications US6,635,301B1 , WO2016/150834 A1 , EP1182937 A4 , WO2009075135 , US20050003071 A1 , WO2016150834 A1 and U.S. 10,716,319 B2 comprehensively described. U.S. 10,716,319 B2 (Method of making a structured protein composition) is considered from a technological point of view as the closest description (closest state of the art) to the inventive technology described in this patent application: (Translated summary from U.S. 10,716,319 B2 ): “The fibrous composition obtained in the extruder exits the extruder at a temperature of the composition that is higher than the applicable boiling temperature of water (e.g. 100°C at atmospheric pressure or lower if a vacuum port is used). It is believed that this leads to expansion and subsequent collapse of the textured product. It is further believed that the expansion/collapse treatment disturbs the fiber orientation and thus leads to the creation of a more random orientation of the formed fibers. In addition, it is assumed that air pockets (on a micro and macro scale) are formed in the textured product. To fine-tune mouthfeel (bite), tenderness and juiciness, after the texturing process, the extruded product can be hydrated in an aqueous liquid at elevated temperatures, i.e. between 40 and 150°C, to a final moisture content of 50 to 95%. Cut tests are most commonly used to measure the tenderness of the extrudates, for example using a Warner Bratzler shear blade // or a Kramer shear cell //. The product of the invention has a heterogeneous structure and a relatively large free volume. This contributes to its relatively high water absorption capacity. This is beneficial because the absorption of aqueous liquids makes it easier to add desired flavor components and allows the product to be varied in terms of juiciness and bite. The extrudate according to the invention is infused into the moist product obtained by extrusion. In contrast to the background art, the extrudate of the present invention does not require drying and rehydration. It remains substantially moist and is then further filled with water or other aqueous composition by infusion. The extrudate preferably has a water content of from 55% to 70% by weight.

The structured vegetable protein composition resulting from infusion with an aqueous liquid preferably has a water content of from 70% to 90% by weight. Surprisingly, the above-mentioned infusion can be enhanced (i.e. drain more quickly and/or allow for incorporation of more water) by an aqueous liquid if the extrudate has been frozen first (and then thawed prior to infusion). Preferably the freezing temperature is below -5°C and -15°C.”

The microfoaming of highly viscous and viscoelastic, dough-like, protein and non-protein-based masses using extrusion processes is discussed in WO 2017/081271 A1 described.

The state of knowledge on food foam systems is, for example, in Peter J. Hailing & Pieter Walstra (1981) Protein-stabilized foams and emulsions, CRC Critical Reviews in Food Science and Nutrition, 15:2, 155203, DPI: 10.1080 /1040839810952 7315 and in Ashley J Wilson (1989) Foams: Physics, Chemistry and Structure; Springer-Verlag London, ISBN 978-1-4471-3809-9.

The production of open-pore foams is known from the plastics/foams industry (N. Mills (2007); Polymer Foams Handbook; Hardcover ISBN: 9780750680 691; Imprint: Butterworth-Heinemann).

Conventional extrusion processes, in particular cooking-extrusion processes in the field of food, building materials and animal feed applications, produce pores that are only reproducible within wide limits and are not reproducible due to the sudden evaporation of water/solvent at the extruder nozzle outlet. The product (extrudate) experiences the formation of a foam-like structure, which is realized by the sudden evaporation of the water as a result of the pressure drop.

In newer extrusion / extrusion-cooking processes, a foamed product can also be formed into one by means of gas metering and gas dispersion or gas dissolution and renucleation of gas bubbles Foam structure lead to better controlled product. However, such products typically have closed pores and, as they flow through the extruder nozzle, form a skin layer that is largely free of foam bubbles and pores due to the maximum shearing near the wall.

For foam extrusion applications, it is essential to control the foam pore structure in order to adjust the product properties in such a way that the ratio of closed and open pores can be adjusted.

In certain applications, e.g. in instant products, open pores enable the desired rapid absorption of liquid by capillary forces, closed pores are desirable when setting the lowest possible product density, obtaining a foamy/creamy mouthfeel (food) or reducing the absorption rate of fluid (foam bubbles as mass transport barriers ).

For a certain range of products from different areas of application, the adjustability of the ratio of closed to open pores is essential for the development of certain quality features. Typical examples of this are fish feed pellets which, in terms of their rate of sinking or their swimming behavior, point to certain species of fish, which typically take up their feed from the bottom of the water body (from floating at a certain water depth or swimming from the surface).

So far, there is no industrially relevant solution for food products with a high content of bound water, such as plant protein-based meat analogues, which have up to > 60% intermolecular water formation, in order to close such on the one hand through defined adjustable (i) microfoam formation and (ii) ratio more open To optimize the consistency of the foam pores and thus to optimize the sensory texture and, on the other hand, to realize an adjustable, additional, particularly production-relevant, rapid (second range) fluid absorption capacity in order to optimize e.g. juiciness and certain further processing properties in e.g.

tasks

The invention is initially based on the object of producing a foamed product with a high bound water content, in the case of extruded meat analogy based on a concentrated vegetable protein melt with > 30% by weight vegetable protein content and > 5% by weight vegetable fiber content and a gas volume content in the end product of > 10 vol. % to create, whereby the gas volume is in the form of pores/bubbles, which should be present in an adjustable proportion as pores open to the product surface, e.g. to accelerate further liquid absorption, with sensory and/or nutritionally relevant components contained in this liquid in the to ensure product.

Furthermore, the invention is based on the object of providing a method with which such products can be produced.

In addition, the invention is based on the object of providing a corresponding device that enables the method.

Finally, there is the object of using such a product, for example for the production of plant protein-based meat analogs/meat alternatives.

Solution of the task concerning a product

This problem is solved by the features of patent claim 1.

Some advantages

The new, foamed products according to the invention allow a coupled adjustment of certain sensory and nutritional attributes as "intrinsic" properties of these products by adjusting the degree of opening of the foam pores, which for conventional products of this category have not been possible to date or only to a small extent through additional products (sauces, toppings, etc.). ) could be achieved. In the case of foamed, plant protein-based meat analogs, the masses for the consumer are thus usual (a) sensory quality attributes: tenderness, juiciness, crispiness, meat taste/aroma, (b) nutritional functionalities (e.g. by introducing bioavailable iron and B vitamins) and (c) convenience properties by enabling or improving the cooking, roasting and grillability made available in a tunable manner.

The formation of a foam structure in a highly viscous to semi-solid product significantly influences its mechanical behavior in the direction of a more easily deformable/softer material. In the case of such products in the food sector, such as extruded, foamed meat analogues based on plant proteins, a less compact, hard or “tender” consistency would be observed as a result of foaming. If (A) is a closed-pore foam system, the compressibility of the gas enclosed in the pores contributes to the deformation behavior of the foam product. When a deforming force is removed, the elastic reverse deformation is supported by the reverse expansion of the gas enclosed in the pores, and also dominates with a high proportion of gas volume. In the case of (B) open-pore foams, the gas in the pores can escape more or less quickly when the foam matrix deforms, depending on the pore size. The deformation behavior of the matrix material forming the foam lamellae thus dominates the macroscopic deformation behavior of the foam product.

In the case of foamed foods, which undergo significant deformation by biting and chewing when consumed, a closed foam pore structure (A) enhances the sensory texture impressions of (i) tenderness (tendemess) but also (ii) gummyness (gumminess) in the case of solid structures of the die Foam lamellae surrounding gas bubbles and (iii) creaminess (creaminess) in the case of fluid foam lamellae properties.

Open-porous, spongy foam structures (B) allow the sensory texture attributes (iv) crunchyness but also (v) brittleness to come to the fore with firm foam lamellar properties. The case of fluid foam lamellar properties is irrelevant for open-pored product systems, since deliquescence of the matrix material leads to a foam with closed pores.

In the case of defined foamed matrices of plant protein-based meat analogues, which have a fixed structure of the foam lamellae surrounding the gas bubbles, consumer wishes/consumer ideas address sensory texture attributes in particular fibrousness combined with tenderness (tendemess) and other important attributes juiciness and Crispness/bite/crispness (crunchiness), often in the context of certain preparation methods (e.g. boiling, roasting, grilling).

In the case of such foamed meat analog products with at least partially open pores, their sensory, nutritional and preparation convenience properties can be significantly expanded in that the pores of the foamed base product are partially or completely filled with functional or functionalized fluids, with such fluids after Pore filling can also solidify. By means of such "fluid fillings" of the open-pored meat analogues, certain taste and aroma-related sensory and/or nutritional product properties and, if necessary, the product stability can be optimized via preserving components.

The filling of open pores can take place, for example, by capillary forces which, given coordinated wetting properties of the filling fluid phase, allow the fluid to be sucked in as a result of the formation of a capillary negative pressure. Since such capillary forces are inversely proportional to the pore diameter, small pore diameters in the range of ≦approx. 500 micrometers are to be preferred.

The subject of the invention is based on an HMEC technology as described above for the preferred production of plant protein-based meat analogues, with this technology being significantly supplemented by a combination with a micro-foaming process, which takes place in the extruder and in a comparable manner, based on the production of foamed baked goods in 121 was described. A defined metered amount of gas (eg N ₂ , CO ₂ ) is first dissolved in the aqueous protein melt in the extruder under the high pressure set there and then expanded again with the pressure being reduced in the extruder cooling nozzle. Gas bubbles are nucleated at the beginning of the extruder nozzle and enlarged as the nozzle flow progresses with progressive pressure release, thus forming a foam structure.

Furthermore, the description of the present subject matter of the invention is based on this foaming technology and its transferability to the production of meat analogues foamed in this way, produced using HMEC technology. The product-related focus of the subject matter of the invention described below is on the plant protein-based (foamed) meat analogues, which make available innovative adjustment options for sensory and nutritional product characteristics of significant consumer relevance through the adjustability of the ratio of closed to the product surface open pores/pore channels.

The cooling of the product flow from the HMEC extruder close to the wall at the entrance to the extruder nozzle, which begins during the production of meat analogues, allows under the still prevailing high pressure and the already noticeably lower temperature near the nozzle wall (from typically approx. 140-160°C to approx. 90 °C) as a result of the improved gas solubility at lower temperatures, fewer foam bubbles form near the nozzle wall.

The (i) high shear of the cooling, foamed protein melt in the vicinity of the nozzle wall supports, in addition to the mentioned effect of (ii) improved gas solubility, a (iii) reduction in gas bubbles due to flow effects (dynamic buoyancy forces) in the nozzle wall zone. The "skin layer" of the extruded, foamed meat-analog strand, which is partially or completely depleted of gas bubbles, shields inner foam pores from the environment. Since, as a result of the typically slow product cooling in the long cooled extruder nozzles used in meat analog HMEC extrusion, there is no longer any significant residual pressure relaxation at the nozzle outlet, a product skin layer formed as described remains closed. For the micro-foamed products this means the existence of a closed foam pore system.

For a number of applications or final product formats, it is advantageous to produce open, spongy pore systems which are able to absorb liquids into the porous (spongy) product matrix through outwardly open pores. Fluids absorbed in such a form can interact with the matrix structure, retain fluid character or solidify or partially solidify under the framework conditions to be set (e.g. temperature). For example, food systems equipped with such open-pored porosity could absorb liquids that impart juiciness to the food in question. For building materials with a corresponding pore structure, suitable fluid systems for impregnation could result in improved resistance to mould/fungus infestation or harmful insects. For applications in wound healing, covering material with a correspondingly open-pored, porous structure can be impregnated with fluids for disinfection or fluid components that promote wound healing.

Against this background, there is great interest in adjusting the pore structure of foamed product systems in an application-specific manner in extrusion processes.

Accordingly, the subject of the invention addresses a technology for adjusting the ratio of closed pores/bubbles to open pores/pore channels that are open towards the product surface. In principle, this can also be achieved mechanically by the connection of originally closed foam bubbles/pores, provided that these can be brought to coalescence or the formation of connecting channels between them and to the product surface in a defined manner, without significant loss of total gas volume fraction and fine pores.

According to the invention, the setting of the pore volume ratio E=ε _OP /ε (ε _OP =porosity of the open pores; ε=total porosity) is achieved in an adjustable manner by means of various specific measures in their individual or coupled application. These pore opening technologies POT _i according to the invention can be found in Table 1 and are described in detail below. No. abbreviation description focusing sharpness POT1 Flash Opening (FOP) Pores are (POT-1.1) opened to the outside by increased residual pressure relaxation and, if necessary, additional (POT-1.2) partial vacuum post-treatment O POT2 Cut Opening (COP) Extruded product strand is cut or skin layers are "peeled off" + POT3 Penetration Opening (POP) Multiple needle penetration at the nozzle exit opens access and connection channels to and between the inner closed pores. ++ POT4 Forced Secondary Mixing-Flow Opening (Mix-Opening, MOP) An adjustable aperture (diaphragm) that specifically uses the flow properties of the product while it is cooling in the extruder nozzle creates so-called secondary flow mixing effects, which turn the inner product areas outwards with an adjustable degree of expression and open or create pore channels/gaps. Viscoelastic fluids such as protein melts allow such flow effects to be generated in an increased and adjustable manner. + POT5 Slow Freeze Opening (FOP) Foam lamellae between closed foam pores are penetrated by ice crystals and thus open pore channels are formed

POT-1:

A slot nozzle aperture (VSDA) with adjustable slot width according to the invention is arranged shortly before the end or at the end of an extruder slot nozzle that may be shortened and narrowed to a position which reduces the static pressure before entry into the narrow slot slot to a value ≥ approx. 1.5-2 bar des after exiting the slot gap, the prevailing static pressure, which is typically atmospheric pressure, can be adjusted. In this procedure according to the invention, the strand of extrudate is not cut off directly at the die outlet, but only from a length of 5-10 cm. The shorter length distance between the middle of the extrusion strand and its surface compared to the length of the extruded product strand up to the strand cutting device is approximately ≦1/2-1/6. According to the invention, this brings about a preferred gas pressure relaxation in the product cross-sectional direction and thus towards the product surface. This is due to the significantly larger pressure gradient realized in this direction compared to that prevailing in the strand length direction. The characteristics of the pore channels formed in the direction of pressure release and their opening outwards towards the surface of the extruded strand is decisively determined by the rheological properties of the extruded product at the time it emerges from the extruder die. Lower viscosity (or elasticity) allows more pronounced material deformation under the effect of the relaxation pressure gradient and, as a result, more pronounced pore channel formation.

The design of the geometry of the adjustable slot nozzle device (VSDA) according to the invention enables a different geometric shaping of the course of the flow cross section in the direction of flow. According to the invention, the constriction is preferably abrupt (approx. 90°), which forces the formation of a secondary flow of the extrusion strand fluid in the zone of the widening again of the flow channel cross section. In this follow-on secondary flow zone, the static pressure is significantly lowered and, on the other hand, a roller-like secondary flow is generated, which causes the strand fluid to be mixed transversely to its direction of flow in the vertical direction of the slot nozzle channel. The "inside-out turn" of the extrusion strand material depends on the intensity of the secondary flow and its frequency of rotation. Since the strand material is located just before the nozzle exit or directly at it, there is no possibility of a renewed formation of a closed skin layer on the product strand, which would lead to renewed pore closure. This results in the formation of pores/pore channels that remain open towards the surface of the extrusion strand.

1. (a) mit eingestelltem Volumenverhältnis von offenen und geschlossenen Poren (Poren-Öffnungsgrad POG),
2. (b) ohne Haut-/Randschichtbildung beim Durchströmen der Extruderdüse
3. (c) mit einstellbaren Textureigenschaften (Zartheit, Knusprigkeit, Saftigkeit)
4. (d) mit erweiterten Möglichkeiten der Geschmacks-/Aroma-/Wirkstoff-Optimierung durch in die offenen Poren aufgenommene Fluidsysteme, welche entsprechende Geschmacks-, Aroma- oder Wirkstoffkomponenten beinhalten, die den Extrusionsprozess nicht durchlaufen, deren Funktionalitätsverminderung damit vermeiden lassen und deren Freisetzung bei Anwendung (Verzehr und Verdauung bei Lebensmitteln, Einnahme von pharmazeutischen Produkten) über die offenen Porenkanäle) beschleunigen.
5. (e) mit erweiterten Möglichkeiten zur „Instant-Produkt“ Herstellung, welche eine beschleunigte Benetzung und Dispergierung in Flüssigkeiten zulassen

The products according to the invention, produced by the method according to the invention using the device according to the invention, make available novel extrusion products with a defined foam structure. These form a practical basis for new product developments:

1. (a) with adjusted volume ratio of open and closed pores (pore opening degree POG),
2. (b) without skin/surface layer formation when flowing through the extruder die
3. (c) with adjustable texture properties (tenderness, crispiness, juiciness)
4. (d) with extended possibilities of taste/aroma/active ingredient optimization through fluid systems incorporated into the open pores, which contain corresponding taste, aroma or active ingredient components that do not go through the extrusion process, thus avoiding their reduction in functionality and their release Accelerate application (consumption and digestion of food, intake of pharmaceutical products) via the open pore channels).
5. (e) with expanded possibilities for "instant product" production, which allow accelerated wetting and dispersion in liquids

More inventive designs

According to patent claims 2 and 3, the basic conditions for the accuracy of setting the degree of pore opening and the underlying total gas pore volume in the product, which should have or should have an open connection to the product surface, are specified. The resulting range from (i) a minimum of 10 vol.% total gas content (in pore form) with 5% open to (ii) a maximum of 80 vol.% total gas content (in pore form) with 90% open is relevant e.g. for foamed meat analogues In order to achieve, in case (i), e.g. easy penetration with intensively flavoring substances in fluid form, and in case (ii) e.g. 72% of the product volume with a fluid phase which gives consistency/texture and which may solidify after filling the pores, to penetrate homogeneously. In the latter case, application to meat analogues resulted in a scaffolding protein structure with e.g. vegan pie/sausage filling. In the area between (i) and (ii), "marbled" product structures with an adapted fat/gel insert can be realized in order to further adjust typical meat/fat/connective tissue/gel structures and associated sensory preferred texture properties.

According to claim 3, the volume fraction filled with gas is limited to 80% by volume, since the pore opening mechanisms according to the invention, which are related to rather solid foam products, can no longer be transferred sufficiently non-destructively to the overall product if the foams are too fragile.

Claims 5 to 6 emphasize the important role of the protein content and the set denatured, possibly anisotropically formed protein structure, since the meat analog products that are preferably considered owe their meat-like texture properties to the denatured, fibrillar protein structures.

Claims 7 to 9 take into account ingredients and their quantities which are of particular importance for the setting of the sensory and nutritional corresponding vegan meat analogues.

Claims 10 and 11 address a surprisingly found special feature of the foamed products according to the invention with an open pore fraction, which represents their volume, shape, structure and texture-related reconstituting work after almost complete drying. The influence of the degree of pore opening has a decisive influence on the acceleration of water transport from the moist product and into the dry product both during drying and during reconstitution.

Solution of the task concerning the procedure

This object is achieved according to claim 12 by the adjustable opening of gas pores/gas bubbles enclosed in the foamed product towards the product surface, with five physical pore opening mechanisms being used individually or in combination according to the invention for defined and controlled pore opening. These methods are: (a) pore opening by rapid ambient pressure drop (flash opening, FOP), (b) pore opening by cutting or peeling the product (CUT opening, COP), (c) pore opening by multiple needle penetration (penetration opening), POP), (d) pore opening by forced secondary mixed flow (Mix-Opening, MOP) and e.) pore opening by freeze structuring (Freeze-Opening, FOP). (b) and (c) are based on mechanical, (a) and (d) on thermodynamic or fluid dynamic mechanisms and e.) on a mixture of both categories.

Some advantages

The method according to the invention and its configurations can be coupled directly to the HMEC extrusion process and the extrusion parameters to be set for structuring the protein matrix for the pore opening can be directly transferred. For the mechanism of (a) pore opening by rapid ambient pressure drop (flash opening, FOP), the static pressure built up in the extruder can be maintained up to the end of the die to such an extent that a sufficiently rapid and efficient residual pressure relaxation can be realized at the pore opening. With the mechanisms (b) pore opening by dividing or peeling the product (CUT-Opening, COP) and (c) pore opening by multiple needle penetration (Penetration-Opening, POP), the movement or kinetic energy of the extrudate strand at the end of the die is used for cutting/ peeling or used for needle penetration. To activate the (d) pore-opening mechanism through forced secondary mixed flow (mix-opening, MOP), part of the kinetic flow energy of the extrudate strand is used to generate a cylindrical secondary flow that also periodically oscillates for viscoelastic masses, which is transverse to the flow in the vertical direction of the extruder Slot nozzle causes a thorough mixing, which elongates closed foam pores, moves them towards the strand surface and "tears open" the surface structure in such a way that the intensity can be adjusted so that a part of the correspondingly treated pores, which can also be adjusted, is opened towards the product surface. The adjustability of the degree of pore opening is based on the adjustability of the intensity of the mixed secondary flow, which in turn can be adjusted within wide limits by adjusting a local slot nozzle height reduction and the transport speed of the extrudate strand. The mechanism (e) for pore opening by freeze structuring is applied according to the invention to foam structures in order to penetrate primarily large ice crystals for penetrating material partitions between closed pores at a preferably slow freezing rate and thus convert them into open pores. The high water content (up to ≤ 60% by weight) of the plant protein-based meat analogues considered as preferred helps to support the formation of ice crystals.

More inventive designs

According to claims 14 to 23, the pore-opening processes are detailed in terms of their technical implementation by means of mechanisms (a)-(e). (a) mobilizes compressive forces to rupture pore boundaries outwards towards the product surface. (b) uses targeted incisions to expose the pore openings. (c) creates connection channels between the closed product pores and outwards to the product surface through needle penetration. (d) refers to the generation of secondary flows in the extruder cooling die in order to break up largely closed product skin layers generated in the laminar slot die flow by cross-mixing in the height coordinate direction of the die channel and to create additional superficial cross-channels/cross-channels. For the protein-rich, meat-analogous product systems, which are primarily addressed, an additional flow-dynamic feature of viscoelastic fluid systems can be advantageously used according to the invention. The so-called elastic turbulence effect (sometimes also referred to as the “melt fracture phenomenon” in the literature relating to plastics processing) arises as a result of the storage of elastic deformation energy in the converging inlet flow of a slot nozzle aperture (VSDA) that is designed according to the invention and arranged in a defined manner in the nozzle channel and is adjustable with regard to the slot channel narrowing. - Contraption. In the diverging outlet flow after the constriction, the previously stored elastic tensile stresses partially relax again through elastic reverse deformation of the viscoelastic fluid (eg a protein melt corresponding to HMEC extruded meat analogues). Small flow asymmetries or the stochastic variance of the elastic deformation cause the formation of a periodic, sinusoidally oscillating, roller-like flow disturbance. As was surprisingly shown on the basis of rheological laboratory measurements for a large number of polymer melts, the secondary flow phenomenon described above develops at a ratio of the first normal stress difference N ₁ to the shear stress τ from a value of N ₁ / τ ≥ 1.5 - 2 and is in a range N ₁ / τ ≈ 4-5 particularly effective in order to use the described inventive effect of the sinusoidal oscillating secondary mixed flow (OSMS) in the wake of a local slot nozzle gap narrowing for cross mixing in the extruder nozzle for the pore opening towards the product surface. The OSMS can thus be set in the range 2≦τw/N ₁ <5 in its method-relevant intensity according to the invention. τw and N ₁ can be measured both in rheometric laboratory measurements using a cone-plate shear gap and in high-pressure capillary rheometric measurements. According to the invention, the latter are also transferred directly to in-line measurements in the extruder slot die. According to the invention, this is done by means of static pressure profile measurements in the die channel before and after the local slot die height reduction or alternatively in the extruder-side die entry zone. According to the invention, the intensity of the OSMS is simplified via the amplitude of the static pressure fluctuation in the slot nozzle channel before or after the local slot nozzle Altitude reduction, measured. The setting of a maximum elastic-turbulent OSMS via an adjustable aperture according to the invention for local slot nozzle height reduction is possibly limited by the fact that an excessively fragmented product strand at the nozzle outlet is to be avoided. This is achieved in that the adjustable slot nozzle aperture (VSDA) device according to the invention is typically installed in the first two thirds of the length of the extruder cooling nozzle. In this way, the elastically-turbulently mixed product strand in the laminar layer flow that re-establishes itself after the aperture is partially evened out again in a defined manner and crack formations in the structure are gradually healed again, if desired. In order to avoid the renewed formation of a skin layer of the product strand with associated pore closure towards the product surface, the degree of OSMS adjustable via the VSDA as described and the length of the extruder nozzle in the aperture wake are matched according to the invention or calibrated specifically for the material system.

Claims 24 and 25 refer to the possibility of drying the products after the pore opening has taken place according to one or a combination of methods (a)-(e) in order thereby to achieve an extended shelf life at ambient temperature storage. According to the invention, the opening of the pores advantageously accelerates the transport of water during drying and also during reconstitution.

Solution to the problem relating to the device

This object is achieved by claim 26 with reference to the five pore opening mechanisms (ae) differentiated according to the invention. The following description of the devices associated with these mechanisms is illustrated by the 1a, b , 2a, b , 3a, b and 4a, b added.

1. (a) Vorrichtungsvariante zur Einstellung eines rapiden Umgebungsdruckabfalls (Flash-Opening, FOP),
2. (b) Vorrichtungsvariante zum Zerteilen bzw. Schälen des Produktes (CUT-Opening, COP) im Austrittsbereich der Extruderkühldüse,
3. (c) Vorrichtungsvariante zur multiplen Nadelpenetration (Penetration-Opening, POP) direkt nach Austritt des teilgekühlten Produktes aus der Extruder-Kühldüse
4. (d) Vorrichtungsvariante zur Erzeugung einer Sekundär-Mischströmung (Mix-Opening, MOP) in der Extruderkühldüse.
5. (e) Vorrichtungsvariante zur Erzeugung großer Eiskristalle zur Schaumlamellen-Penetration mittels Gefrierstrukturierung (Freeze-Opening, FOP) in einer Nachbehandlung zur Quench-Kühlung nach Extruderkühldüsenaustritt, welche in einzelner oder gekoppelter Anwendung zu nutzen sind.

The pore opening mechanisms addressed according to the invention use mechanical, fluid mechanical or thermodynamic principles to open closed pores to the product surface by means of a:

1. (a) device variant for setting a rapid drop in ambient pressure (flash opening, FOP),
2. (b) Device variant for cutting or peeling the product (CUT-Opening, COP) in the exit area of the extruder cooling nozzle,
3. (c) Device variant for multiple needle penetration (penetration opening, POP) directly after the partially cooled product exits the extruder cooling nozzle
4. (d) Device variant for generating a secondary mixed flow (mix opening, MOP) in the extruder cooling nozzle.
5. (e) Device variant for generating large ice crystals for foam lamella penetration by means of freeze structuring (freeze opening, FOP) in a post-treatment for quench cooling after extruder cooling nozzle exit, which can be used in individual or coupled applications.

The core element of the devices for activating the pore opening mechanisms according to (a) and (d) is a variable slot nozzle aperture (VSDA). Their free cross-sectional area for the passage of the extrudate corresponds exactly to the dimensions of the free cross-section of the extruder slot nozzle when it is 100% open. In the case of a flat, right-angled extruder nozzle slot channel, a cut, rotatably slide-mounted metal cylinder (2) is embedded in the aperture housing (1) in the upper and lower wall delimiting the throughflow slot of the aperture device over the entire slot width, at right angles to the direction of flow. When the aperture is fully open, the gate surfaces of these cylinders are flush with the flow channel wall (3). From outside the aperture housing (1), the metal cylinders (2) can be rotated manually or by means of two servomotors in a controlled or regulated manner so that the aperture narrows on one side or is symmetrical to the longitudinal axis of the nozzle, which at a twist angle of 90° corresponds to the maximum degree of closure corresponds to the slot channel cross section (further details, see description of the figures, 1 ).

Activation of the pore-opening mechanism d) to generate a secondary mixed flow (mix-opening, MOP) in the extruder cooling nozzle can be carried out solely by means of the VDSA device. In case (d), this is integrated into the nozzle at a position between 10-95% of the nozzle length measured from the nozzle exit end. In the case of a severely disintegrated extrudate structure, this ensures that this reintegrates to a part on the remaining stretch of the die after the passage through the aperture, thus preventing the extrudate strand from disintegrating at the die outlet.

To utilize the pore opening mechanism (a) as a result of sudden residual pressure release, the VDSA device is integrated into the nozzle in a position between 0-10% of the nozzle length measured from the nozzle outlet end. This ensures that the abrupt relaxation of the static residual pressure and thus the opening of the pores towards the extrudate surface only takes place shortly before the nozzle exit or directly at the nozzle exit.

If the extrudate is additionally suddenly subjected to a partial vacuum to open the pores, cut off extrudate parts are post-treated in a separate, quasi-continuously operating vacuum device directly after the nozzle outlet. This additional treatment variant is preferably carried out with softer extrudates which, in the case of protein-based meat analogs, have a higher die outlet temperature or a higher water content.

When using the pore opening variant (c) for multiple needle penetration (penetration opening, POP) directly after the partially cooled product has exited the extruder cooling nozzle, two counter-rotating hollow needle or barbed felt needle rollers are attached in the preferred embodiment of the device at the extruder nozzle outlet that the needles penetrating the extrudate from both sides mesh and the rotation of the needle rollers preferably takes place without an auxiliary drive, solely by the feed of the extrudate through the gap between the two needle rollers (for further details see the description of the figures, 5 ).

When using the pore opening variant (c) by cutting or peeling the product (CUT-Opening, COP) in the exit area of the extruder cooling nozzle, a cutting/paring knife arrangement is arranged shortly before exiting or directly at the exit of the extrudate strand from the extruder nozzle. The extrudate strand feed is thus used to implement the cutting forces. Internal foam pores are thus opened towards the newly created product surface. This is particularly indicated when a "skin layer" with fewer foam pores has formed in the jet flow.

Some advantages

With the exception of the additional vacuum application to activate the pore-opening mechanism (a) to set a rapid drop in ambient pressure (flash-opening, FOP), and the freeze structuring to activate the pore-opening mechanism (e) to penetrate the pore wall using ice crystals (freeze-opening FOP), all other devices are simple constructed and arranged directly in or coupled to the extruder nozzle. This results in the particular advantage of the direct linkability of these mechanisms and the associated device variants. All of these devices are insensitive to contamination, mechanically robust and easy to preset so that no further manipulations are required during the production process.

The pores can be opened effectively and reproducibly by means of the devices configured according to the invention, with the quality and degree of the pores being opened still being determined by the material behavior of the extrudate. This must have a basic strength or yield point which ensures that the open pores created are not closed again by the matrix mass flowing together. Due to the fact that the pore opening mechanisms (a)-(e) can be superimposed in an advantageous manner according to the invention and the devices according to the invention provided for this purpose, a sufficient pore opening efficiency can also be ensured for critical, soft extrudates.

More inventive designs

1. (a) und (d) werden über die Anwendung der Verstellbaren SchlitzDüsenApertur (VSDA) wie in den Ansprüchen 27 und 30 bis 34 ausgeführt bestimmt, mit gegebenenfalls zusätzlichem Einsatz einer Nachvakumier-Vorrichtung im Falle (a) wie in Anspruch 27 einbezogen wird.

According to claims 26 to 35, the devices for opening the pores by means of the mechanisms (a) - (e) are further detailed in their device-technical explanations.

1. (a) and (d) are determined via the use of the Adjustable Slot Nozzle Aperture (VSDA) as set out in claims 27 and 30 to 34, with the optional additional use of a post-vacuum device in case (a) as included in claim 27.

The device for applying the pore-opening mechanism (b) by means of cutting or peeling the product (CUT-Opening, COP) is described in claim 28.

Claim 29 refers to the device for using the pore opening mechanism (c) by means of needle penetration.

Claim 35 describes the device frame for performing the pore opening by means of freeze structuring according to mechanism (e).

Further detailed information regarding the design of the devices for opening the pores is given in the description of 2-7 given.

Solution of the task regarding the use

This object is solved by claims 36 and 37. These refer to the preferred use of the products according to the invention as plant protein-based meat analogues or main components thereof and also contain menus produced using the method according to the invention using the device according to the invention.

More inventive designs

Claim 38 shows the expandable application of the product, process and device configurations according to the invention to other foamed or foamable food product groups, which benefit from a foam pore opening for expandable options for quality and functionality adjustments.

Some advantages

Fibril-structured meat analogues that can be produced on a vegetable protein basis using High Moisture Extrusion Cooking (HMEC) technology to date have a compact structure that does not come close enough to the comprehensive sensory requirements of consumers for really comparable texture, taste and some nutritional properties of meat to be considered as real alternative to be accepted. The product structures that can be achieved according to the invention with an adjustable ratio of closed and open pores allow the attributes required for meat analogues to be met by being used purposefully on the one hand to give a positive texture (tenderness, crispiness) and on the other hand to give taste (juiciness) via the simple absorption capacity of fluid systems. The fundamental non-restriction of the technology package according to the invention to meat analogues also creates a broad implementation horizon for other foamed food systems. Implementations on pharmaceutical and cosmetic products as well as on construction/construction materials are also application horizons that can be notified.

• 1 zeigt die erfindungsgemäße Verstellbare SchlitzDüsenApertur (VSDA) für eine flache Schlitzdüse. In 1 gelten folgende Bezeichnungen: 1 = Apertur-Gehäuse, 2 = angeschnittener drehbar gleitgelagerter Metallzylinder - 2a in 0-Stellung mit freiem Strömungsquerschnit, 1b in Uhrzeigerrichtung gedreht, 2c in Gegenuhrzeigerrichtung gedreht, 3 = Schlitzdüsenwand, 4a - 4c = Apertur-Einlaufströmung für die verschieden gedrehten Metallzylindereinstellungen gemäß 2a-2c, 5a - 5c = Apertur-Auslaufströmung für die verschieden gedrehten Metallzylindereinstellungen gemäß 2a-2c, 6 = Geometrische Bezeichnungen zur Positionierung der Metallzylinder, α = Drehwinkel der Metallzylinder, β = Winkel zwischen Metallzylindermittelpunkt und Kanten der Anschnittfläche des Metallzylinders.

In the drawing, the invention is illustrated, for example, partly schematically. Show it:

• 1 shows the Adjustable Slot Nozzle Aperture (VSDA) according to the invention for a flat slot nozzle. In 1 the following designations apply: 1 = aperture housing, 2 = cut, rotatable, slide-mounted metal cylinder - 2a in 0 position with free flow cross-section, 1b turned clockwise, 2c turned counterclockwise, 3 = slot nozzle wall, 4a - 4c = aperture inlet flow for the different rotated metal cylinder settings according to 2a-2c, 5a - 5c = aperture outlet flow for the various rotated metal cylinder settings according to 2a-2c, 6 = geometric designations for positioning the metal cylinders, α = angle of rotation of the metal cylinders, β = angle between the center of the metal cylinder and the edges of the gate surface of the metal cylinder .

The calculation bases for the defined reduction in height of the extruder nozzle flat slit channel as a function of the rotation angle δ of the metal cylinder to be rotated and as a function of the metal cylinder radius R1 as well as the placement of the gate surface (angle β) and the center coordinate R1 of the metal cylinder that is thus determined are in 8th executed.

In the case of a flat, right-angled extruder nozzle slot channel, in the upper and lower wall delimiting the through-flow slot of the aperture device, a cut, rotatable, slide-mounted metal cylinder (2) can be sealed in the aperture housing (1) over the entire slot width, but can be rotated at right angles to the direction of flow admitted. When the aperture is fully open, the gate surfaces of these cylinders are flush with the flow channel wall (3). From outside the aperture housing (1), the metal cylinders (2) can be rotated by hand or by means of two servomotors, so that the aperture is narrowed on one side or symmetrically to the longitudinal axis of the nozzle, which corresponds to the maximum degree of closure of the slot channel cross-section at a twist angle of 90°.

In the case of a ring slot die, which is used for increased extrudate mass flows, the mechanism of the slot gap height adjustment is a concentric conical design of inner wall of the nozzle housing and an axially displaceable plunger with a conical tip, as in 2 represented, realized.

For 2 the following designations apply: 7 = conical nozzle housing, 8 = axial gap setting stamp with conical tip, 9 = setting stamp guide tube, 10 = tempering fluid inlet into setting stamp guide tube, 11 = tempering fluid outlet from setting stamp guide tube, 12 = tempering fluid channels in inner (12a ) and outer (12b) nozzle housing walls as well as in the setting stamp (12c), 13 = guides for axial setting stamp guide tube, 14 = nozzle gap in initial position (14a) and with narrowed gap setting (14b), 15 = annular slot nozzle inner housing wall part, 16 = flange for connection of ring die parts or with extruder housing

For the additional post-treatment according to the application of the pore-opening mechanism (a) for pore opening by means of a rapid drop in ambient pressure (flash opening, FOP) by means of partial vacuum application, the device according to the invention is used as in 3 shown, used.

For the designations in 3 apply: 17 = slot nozzle flow channel, 21 = extrudate strand, 26 = partially perforated conveyor belt, 27a = upper vacuum half-shell, 27b = lower vacuum half-shell, 28a = contact pressure pneumatics for upper vacuum half-shell, 28b = contact pressure pneumatics for lower vacuum Half shell, 29 = cut extrudate part, 30 a,b = piping for suction (partial vacuum transfer), 31 = partial vacuum storage tank, 32 = vacuum pump, 33 = strand cutter

POT2: The device implemented according to the invention for opening the pores according to mechanism (c) by cutting or peeling the product (CUT-Opening, COP) applies a cutting/peeling knife (possibly water jet or laser cutting devices) in the exit area of the extruder cooling nozzle - arrangement as shown in the diagram in 4 shown.

As designations in 4 apply: 17 = slot nozzle flow channel, 18 = laminar slot nozzle flow, 19 = cutting device for positioning above the slot channel height H, cutting device for positioning above the slot channel width W

POT3: The device for realizing the pore opening according to mechanism (c) for multiple needle penetration (Penetration-Opening, POP) is arranged directly after the extruder nozzle exit and combines in the preferred embodiment of the device according to the invention two counter-rotating hollow needle or barb felt needle rollers, where the needles penetrating the extrudate from both sides as in 5 illustrated, intertwine.

As designations in 5 apply: 17 = slot nozzle flow channel, 22a = upper needle roller, 22b = lower needle roller, 23 = penetration needle (hollow needle or barbed felting needle), 24 = conveyor belt dividing device, 25 a,b = upper, lower penetrating needle rollers pressing-on dividing device (pneumatic/hydraulic /mechanically).

POT-4: The device for realizing the pore opening according to mechanism d) for generating a secondary mixed flow (Mix-Opening, MOP) in the extruder cooling nozzle can in principle be limited to the Adjustable Slot Nozzle Aperture (VSDA) device for in-line control of the Intensity of the set secondary mixed flow, however, the coupling with a measuring arrangement according to the invention for determining the static pressure before and after the VSDA device is indicated. This pressure measurement arrangement is in combination with the VDSA device in the 6 and 7 shown.

7 includes an extension of the pressure measurement arrangement 6 in the case of viscoelastic fluids, such as those found in the case of protein melts for the production of meat analogs.

As designations in the 6 and 7 apply: 1 = aperture housing, 2 = cut, rotatable, slide-mounted metal cylinder - 2b rotated clockwise, 3 = slot nozzle wall, 4b = aperture inlet flow for rotated metal cylinder clockwise (2b), 5b = aperture outlet flow for rotated metal cylinder clockwise (2b) , 17 = slot nozzle flow channel, 35 = membrane pressure sensor for static pressure measurement P1; 36 = membrane pressure sensor for static pressure measurement P2, 37 = membrane pressure sensor for static pressure measurement P3, 38 = membrane pressure sensor for static pressure measurement P4, 39 = pressure sensor membranes, 40 = connecting flanges, 41 = conical nozzle inlet flow geometry, 42 = membrane pressure sensor for static pressure measurement P5, 43 = P5 - pressure measurement cavity.

For pronounced viscoelastic extrusion fluids, such as those corresponding to foamed protein melts, for example, the aforementioned VSDA is installed according to the invention at a greater distance from the die outlet in the extruder die than in the POT-1 technology. In the case of viscoelastic product fluid systems, the aforementioned secondary flows as a result of adjustable channel cross-section narrowing and widening are significantly forced by the effect of elastic turbulence (relaxation of the elastic extra-normal stresses and the resulting reverse deformation of the strand). This effect can be triggered even with a slight narrowing of the slot nozzle cross-section and its expression can be set and used in a targeted manner to create an open pore structure.

For this purpose, according to the invention, as in 6 shown, static pressure measurements at a position in the extruder housing in front of the nozzle inlet cross section (P1) at two longitudinal positions in the extruder slot nozzle (P2, P3) after the nozzle inlet zone (after conical narrowing), after the VSDA (P4), and (P5) in the slot nozzle channel before the VSDA , directly opposite (underside of slot nozzle channel) to pressure measuring position P2.

From P2 and P3, the local shear stress τw on the slot nozzle channel wall and, knowing the product volume flow dV/dt determined at the nozzle outlet, the product shear viscosity η can be determined. With the inclusion of P1, it is possible to determine _a nozzle inlet pressure loss ΔP in, which consists of the sum of (i) a viscous extensional pressure loss ΔP _D,in under the effect of the extensional viscosity of the extruded fluid and (ii) an elastic pressure loss component ΔP _E, in as a result elastic energy storage, results. By means of the additional static pressure measurement P5, a purely elastic parameter fluid response can be determined between the measuring points for P5 and P2 from P5-P2 through reverse deformation as a result of elastic stress relaxation. P2-P5 is proportional to the so-called first normal stress difference N1, which is measured in rheometric laboratory measurements using the cone-plate shear gap geometry and can be compared with the values determined in-line or a calibration can be derived from them. The elastic component DP _E,in of the nozzle inlet pressure drop ΔP in can _be determined from P2-P5, and the complementary viscous expansion component ΔP _D,in of ΔP _{in is} also obtained. The arrangement according to the invention of the pressure measurement points P1-P3 and P4 means that there are separate rheological parameters for (a) the shear viscosity, (b) the elongational viscosity and (c) the elasticity of the extruded mass under the given extrusion conditions. In the case of the pressure measurement P5, it should be noted that this is not carried out like all other pressure measurements (P1-P4) via a membrane of the pressure sensor flush with the wall in the slot die channel, but at the end of a cavity filled with the extrusion fluid, which is used to measure the first normal stress difference from P2 -P5 has a (narrow) rectangular cross-section extending in the direction of flow (eg: with a nozzle channel width of 60 mm: 10 x 50 mm). The pressure measurement P4 takes place at a position in the slot nozzle channel immediately after the constriction created by the VSDA device (reduction in height of the slot nozzle channel ΔH). In this way, periodic, static pressure fluctuations DP4(t) generated in particular by a forced secondary mixed flow in the VSDA wake are recorded. According to the invention, these are a measure of the mixing intensity and the associated foam pore opening efficiency according to the mechanism (d) identified and described above.

As was surprisingly found in laboratory rheometric measurements for a large number of polymer fluid systems, the "elastic turbulence phenomenon" (also called melt fracture in the plastics industry) shows up in a certain range of the ratio of the first normal stress difference to the shear stress N ₁ (γ _w )/τ(γ _w ) at wall shear rate g _w effective on the slot nozzle channel wall. This range is 2 ≤ N ₁ (γ _w )/τ(γ _w ) <5. The expression of the elastic turbulence effect used according to the invention for using the mechanism (d) according to the invention of the foam pore opening by forced secondary mixed flow preferably takes place in the range 2 ≤ N ₁ (γ _w )/τ(γ _w ) < 3.5-5. As this ratio value increases, the secondary mixed flow effect is gradually increased. Depending on (i) the rheology of the extruded fluid system (here preferably vegetable protein-based melt for meat analog production) and the mean flow velocity in the slot nozzle channel, the VSDA device is adjusted with regard to the slot nozzle height reduction in such a way that the intended degree of secondary mixed flow with a correlated pore opening effect results. Thus, by means of material system-specific calibration, a quantitative criterion for setting the VSDA slot opening to trigger or set a gradual expression of the forced "elastic-turbulent secondary flow mixing effect" can be determined, which leads to the pore opening according to the invention using the POT-4 technology and the thus triggered Mechanism (d) enabled in an adjustable manner.

The development of the viscoelastic secondary flow effect used for POT-4 can lead to an almost complete disintegration of the extrudate strand. In plastics technology, this undesirable elastic phenomenon is also referred to as "melt fracture". To avoid this, the VSDA device according to the invention >0.2 L _D (L _D = nozzle length) installed before the end of the extruder nozzle. The consequence of this is that the extrudate strand, in the event of partial disintegration in the undisturbed nozzle flow after passing through the VSDA, "heals" again to such an extent that a compact, cohesive, foamed, partially open-pored product strand results without the through repeated flow-related "skin formation". destroying the pore opening effect achieved by elastic-turbulent mixing.

Exemplary representations of plant protein-based meat analog product structures and pore opening degrees achieved with the devices according to the invention using the method according to the invention are given in FIGS 8-10 described below.

• HMEC Extruder: Corotating Twin Screw BCTL Extruder der Bühler AG mit Schneckendurchmesser 42 mm und einem Extruderlängen zu Schneckendurchmesser Verhältnis von L/D = 28.
• Extruder Kühldüse: L = 1.85m, W = 60 mm, H = 15 mm
• Material/Basis-Rezeptur: 52.5% Wasser, 0.5% Öl, 41.2% Erbsenprotein-Isolat (PPI), Erbsenfaser 5.8%
• Prozessbedingungen: Schneckendrehzahl: 230 rpm; Massenstrom 37.5 kg/h; Düseneintrittstemperatur der Schmelze: 150°C; Extruderaustrittsdruck: 18 - 20bar, Düsen Kühltemperatur: 60°C

The basic conditions for the examples given below are:

• HMEC extruder: Corotating twin screw BCTL extruder from Bühler AG with a screw diameter of 42 mm and an extruder length to screw diameter ratio of L/D = 28.
• Extruder cooling nozzle: L = 1.85m, W = 60mm, H = 15mm
• Material/basic recipe: 52.5% water, 0.5% oil, 41.2% pea protein isolate (PPI), pea fiber 5.8%
• Process conditions: screw speed: 230 rpm; mass flow 37.5 kg/h; Nozzle entry temperature of the melt: 150° C.; Extruder outlet pressure: 18 - 20bar, nozzle cooling temperature: 60°C

Example 1 (p. 9 ): Pore opening mechanism by means of (a) sudden residual pressure release and (d) superimposed forced secondary mixed flow.

• • : ΔH ≈ 5% / resultierender Porenöffnungsgrad POG ≈ 3 - 5%
• • : ΔH ≈ 10% / resultierender Porenöffnungsgrad POG ≈ 10 -12%
• • : ΔH ≈ 50% / resultierender Porenöffnungsgrad POG ≈ 25 -30%

Different degrees of pore opening were adjusted by means of the superimposed pore opening mechanisms by (a) rapid pressure drop (static residual pressure relaxation) and (d) forced secondary mixed flow, generated by means of the adjustable slot nozzle aperture (VSDA) installed at the nozzle outlet end with different settings of the slot channel height reduction ΔH / % :

• • : ΔH ≈ 5% / resulting degree of pore opening POG ≈ 3 - 5%
• • : ΔH ≈ 10% / resulting degree of pore opening POG ≈ 10 -12%
• • : ΔH ≈ 50% / resulting degree of pore opening POG ≈ 25 -30%

• POG = VOP Volumen der offenen Poren/VGP Gesamtporenvolumen. VOP wurde ermittelt, indem eine extrudierte Probe für 5 s in Wasser bei Raumtemperatur (25°C) eingelegt und nach Entnahme der Strangoberfläche anhaftendes freies Wasser mittels Haushaltspapier in einem definierten schnellen Handhabungs-Procedere durch beidseitig einmaliges Auflegen auf eine Lage des Papiers für jeweils 1s, oberflächlich abgetrocknet. Aus der Differenzwägung vor und nach solcher Behandlung resultierte die in zur Produktoberfläche hin offene Produktporen durch Kapillarkräfte eingesaugte Wassermasse. Die Bestimmung von VGP erfolgte durch Volumen und Masseermittlung des extrudierten Produktes, woraus im Vergleich zum nicht geschäumten Produkt der Gasvolumenanteil bzw. Overrun (= relative Volumenzunahme durch Aufschäumung) ermittelt wurde.

The degree of pore opening (POG) was determined according to:

• POG = VOP open pore volume/VGP total pore volume. VOP was determined by placing an extruded sample in water at room temperature (25°C) for 5 s and, after removing the strand surface, free water adhering to it using household paper in a defined, quick handling procedure by placing it on both sides once on a layer of paper for 1 s each , superficially dried. The difference in weight before and after such treatment resulted in the mass of water sucked into the product pores, which are open towards the product surface, by capillary forces. VGP was determined by determining the volume and mass of the extruded product, from which the proportion of gas volume or overrun (= relative increase in volume due to foaming) was determined in comparison to the non-foamed product.

As 9 it can be seen that the extrudate surface shows increasing "fissures" with increasing VSDA slot die channel height reduction, as a result of the imposed forced secondary mixed flow with simultaneous residual pressure relaxation. This is a typical image of the resulting product when installing the VSDA at the nozzle end.

The samples taken into account in this example, untreated with regard to pore opening, had a gas volume fraction after foaming of approx. 25-35% by volume in ≧approx. 98% closed inner foam pores.

Example 2 (p. 10 ): Pore opening mechanism by means of (d) forced secondary mixed flow, generated by means of an adjustable slot nozzle aperture (VSDA) installed at a nozzle length of 0.75 m from the nozzle outlet when the slot channel height reduction is set DH / % ≈ 15%.

10 shows a predominantly smooth extrudate surface with clearly visible flow patterns, which originate from the forced secondary mixed flow. These "heal" as a result of the subsequent jets flow (here over a further 0.75m of the nozzle length). This reduces the degree of pore opening achieved for the end product to a small extent, but allows the production of quality-relevant structural patterns from the consumer’s point of view, which reflect a natural distribution of structural inhomogeneities such as in meat products (in Example shown: Salmon/fish or marbled Wagyu beef structures) The degree of pore opening achieved under the boundary conditions selected in this example is 18-20%.

The samples taken into account in this example, untreated with regard to pore opening, had a gas volume fraction after foaming of approx. 15% by volume in ≧approx. 98% closed inner foam pores.

Example 3 (p. 11 ): Pore opening mechanism by means of (d) forced secondary mixed flow, generated by means of an adjustable slot nozzle aperture (VSDA) installed with a nozzle length of 0.3 m from the nozzle outlet when setting the slot channel height reduction DH / % = 15%.

shows an enlarged image of the product surface. The wavy stripe pattern structures are clearly visible. (H) lighter (more foamed) and (D) darker (less foamed) areas alternate in strips. The H areas originate from the inner strand foam structure, which is conveyed to the product surface by the forced secondary mixed flow. The D-areas originate from the original "surface skin layer" which was depleted of foam pores.

The samples taken into account in this example, untreated with regard to pore opening, had a gas volume fraction after foaming of approx. 30% by volume in ≧approx. 98% closed inner foam pores. The degree of pore opening (POG) achieved is approx. 18-20%.

Example 4 (p. 12 ): Pore opening by means of (b) cutting/peeling mechanism produced by means of an adjustable cutting device installed at the end of the nozzle outlet.

12 shows a foamed, continuously cut strand of extrudate. Open pore structures can be detected on the cut surface. A pore opening degree of approx. 10-15% was achieved in the example shown. The extrudates on which this example is based had a gas volume fraction of approx. 15-20%.

A total volume of open pores of 2-5% is rated as sufficient for enriching the plant protein-based meat analogues described as an example with sensory (aroma, taste) and nutritional (B vitamins, minerals (Fe, Zn)). ≥ 10% are relevant for increasing product juiciness, depending on the water content of the product matrix.

The features described in the patent claims and in the description and evident from the drawing can be essential for the realization of the invention both individually and in any combination.

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QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• US6635301B1 [0009]
• WO 2016/150834 A1 [0009]
• EP 1182937 A4 [0009]
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• WO 2016150834 A1 [0009]
• US 10716319 B2 [0009]
• WO 2017/081271 A1 [0011, 0105]
• DE 102016111518 A1 [0105]

Claims (38)

Foamed, elastic, protein-based product with a dry matter content of 20-60% by weight, bound water content of ≥ 40% by weight and gas pore structure, with the ratio of gas-filled pores (OP) open towards the product surface to closed, gas-filled pores ( GP) is set in the range of 0.05 - 0.9. product after claim 1 , characterized in that the degree of pore opening for values ≥ 0.1 is set with an accuracy of +/- 0.05. product after the claims 1 and 2 , characterized in that the gas volume fraction (= porosity) is also set between 0.1 and 0.8 with an accuracy of +/- 0.05. product after claim 1 and one or more of the subsequent claims, characterized in that the product has a protein content of 10 - 95% in its dry substance. product after claim 1 and one or more of the following claims, characterized in that the protein content consists of 0 - 100% vegetable protein. product after claim 1 and one or more of the subsequent claims, characterized in that the protein in the product is present in partially to completely denatured form and preferably has a fibrillar structure, more preferably an oriented fibrillar structure. product after claim 1 and one or more of the subsequent claims, characterized in that the product contains a plant fiber content of 0.5 - 20% by weight, based on total dry matter. product after claim 1 and one or more of the subsequent claims, characterized in that the product contains a proportion of fats/oils of 0.1 - 15% by weight, based on the total dry matter product after claim 1 and one or more of the following claims, characterized in that the product contains a proportion of flavoring and/or coloring and/or components that increase the nutritional value in addition to the plant fiber proportion of 0.1 - 5% by weight, based on total dry matter. product after claim 1 and one or more of the subsequent claims, characterized in that the product, after gentle drying to a residual water content of ≤ 5% and spoilage-free, several months of moisture-controlled storage under room temperature conditions, when it comes into contact with water or a water-containing fluid system, restoring its original volume and its Texture reconstituted without significant loss of dry matter. product after claim 1 and one or more of the subsequent claims, characterized in that the product, after gentle drying to a residual water content of ≤ 5% and spoilage-free, has been stored for several months under humidity-controlled conditions under room temperature, when brought into contact with an aqueous fluid system which contains functional, sensory and/or nutritionally relevant components contains, restoring its original volume and texture, reconstituted and interspersed throughout its volume with the functional components. Process for the manufacture of a product according to claim 1 and one or more of the subsequent claims, characterized in that the method implements the opening of gas pores/gas bubbles enclosed in the foamed product towards the product surface in an adjustable manner. procedure after claim 1 or one of the preceding claims, characterized in that an extrusion process of the "High Moisture Extrusion Cooking" type (High Moisture Extrusion Cooking, HMEC) is preferably used as a basis and the five mechanical opening mechanisms for pore opening: (a) Opening by rapid ambient pressure drop (flash opening , FOP), (b) opening by cutting or peeling the product (cut-opening, COP), (c) opening by multiple needle penetration (penetration-opening, POP), (d) opening by forced secondary mixed flow (mix- Opening, MOP) and (e) freeze-opening (FOP) can be applied individually or in combination. procedure after claim 1 or one of the preceding claims, characterized in that the opening of closed pores towards the product surface by means of the opening mechanisms (c) by multiple needle penetration (penetration opening, POP) and (e) by freeze structuring after the partially cooled product has exited the extruder cooling nozzle, by means of the opening mechanisms (a) by rapid ambient pressure drop (flash opening, FOP) and (b) by dividing or peeling the product (CUT opening, COP) in the exit area of the extruder cooling nozzle and the opening mechanism (d) by forced secondary mixed flow ( Mix opening, MOP) in the extruder cooling nozzle. procedure after claim 1 or one of the preceding claims, characterized in that the opening of closed pores to the product surface by means of (a) rapid drop in ambient pressure (flash opening, FOP) by maintaining the static pressure until just before the nozzle exit at a pressure level ≥ 2 bar by means of an adjustable slot nozzle Aperture (VSDA), which is installed at the extruder nozzle outlet or just (≤ 10 cm) in front of it, depending on the viscosity of the exiting fluid mass, is adjusted to a static pressure prevailing in front of the VSDA in such a way that the opening of inner pores to the product surface is also set to a product-specific setting The number of pores open towards the product surface relative to the total number of closed and open pores is given. procedure after claim 1 or one of the preceding claims, characterized in that the opening of closed pores towards the product surface by means of (a) pore opening by rapid ambient pressure drop (flash opening, FOP) by sudden application of a partial vacuum of ≤ 100 mbar for an extrudate strand part after it has been cut off, in a quasi-continuous vacuum chamber device. procedure after claim 1 or one of the preceding claims, characterized in that closed pores are opened towards the product surface by means of (b) dividing or peeling the product (CUT-Opening, COP) by continuously cutting the extrudate strand over a cutting device installed at the end of the extruder slot die is cut open, or its surface layers are peeled off. procedure after claim 12 and one or more of the foregoing Claims 13 - 14 , characterized in that closed pores are opened towards the product surface by means of (c) multiple needle penetration (penetration opening, POP) and connection channels with diameters of 0.1-2 mm are produced between inner closed pores/bubbles and the product surface. procedure after claim 12 and one or more of the foregoing Claims 13 - 14 , characterized in that the opening of closed pores towards the product surface takes place by means of the mechanism according to the invention of (d) forced secondary mixed flow (mix opening, MOP), with local narrowing of the cross section of the extruder slot nozzle by means of an adjustable slot nozzle aperture (VSDA ) via an adjustable slot gap height reduction made according to the invention, in the wake of the constriction produced, a roller-shaped secondary flow, which is also adjustable in terms of intensity and associated mixing efficiency in the direction of the slot height extension of the nozzle gap, is generated, with the roller flow axes of rotation being aligned across the nozzle slot width transversely to the main flow direction. procedure after claim 12 and one or more of the foregoing Claims 13 - 14 and 19, characterized in that closed pores are opened towards the product surface by means of the mechanism according to the invention of (d) forced secondary mixed flow (mix opening, MOP), whereby for viscoelastic aqueous protein melts and other viscoelastic fluid systems by local narrowing of the cross section of the extruder slot nozzle by means an adjustable slot nozzle aperture (VSDA) built into this in the wake of a constriction made by means of this adjustably by reducing the slot nozzle height, a roller-shaped, periodically fluctuating secondary flow that is also adjustable in terms of its intensity and associated mixing efficiency in the direction of the slot height extension of the nozzle gap is generated, with alignment of the roller flow Rotational axes across the nozzle slot width transverse to the main flow direction, and by means of an inventive in-line measurement of the amplitude of the sinusoidal oscillating temporal, static Pressure curve before or after the VSDA, the degree of intensity of the secondary flow mixing effect is quantitatively described and gradually adjusted by adjusting the nozzle slot gap width within the VSDA device. procedure after claim 12 and one or more of the foregoing Claims 13 - 14 and 19-21, characterized in that the gap narrowing by adjusting the height of the slot using the adjustable slot nozzle aperture (VSDA) according to the invention in accordance with viscous and elastic material parameters of the extruded fluid mass measured rheometrically in-line or off-line in a cone-plate shear gap under extrusion conditions takes place, the viscous properties being described by the shear stress τ as a function of the shear rate γ, the elastic properties by the first normal stress difference N ₁ as a function of the shear rate y, and the narrowing of the slot nozzle gap is carried out according to the invention in such a way that for the ratio N ₁ / τ under the apparent wall shear rate ysw prevailing in the narrowed slot nozzle gap, the relationship: 2 ≤ (N ₁ /τ) < 5 applies. procedure after claim 12 one or more of the foregoing Claims 13 - 14 and 21, characterized in that the in-line measurement of the static pressure profile before or after the VSDA only simplifies the amplitude of the oscillatory fluctuations in the static pressure as a basis for adjusting the narrowing of the slot gap, the secondary flow mixing effect thus generated in the aperture wake flow and the associated opening of inner closed foam pores to the slot die wall and thus to the extrudate surface as well as the creation of new pore channels or gaps open to the product surface. procedure after claim 12 and one or more of the foregoing Claims 13 - 14 , characterized in that closed pores are opened towards the product surface by means of (e) freeze structuring, with rapid cooling of the product taking place after exiting the extrusion die and post-cooling treatment in the temperature range between -1 and -20°C, preferably with periodic temperature control within these limits he follows. procedure after claim 12 and one or more of the preceding claims, characterized in that the product, after the partial opening of the pores, is gently dried to a residual water content which allows several months of moisture-controlled product storage at room temperature without causing microbiological or enzymatic spoilage. procedure after claim 12 and one or more of the preceding claims, characterized in that the product is reconstituted by water/fluid absorption after partial opening of the pores and gentle drying to a residual water content which allows the product to be stored at room temperature under moisture-controlled conditions for several months. Device for carrying out the method according to claims 14 and one or more of the foregoing Claims 15 - 23 , characterized in that the device implements a mechanical, fluid-mechanical or thermodynamic principle of action in order to open closed pores towards the product surface by means of (a) a device variant for setting a rapid drop in ambient pressure (flash opening, FOP), (b) a device variant for dividing or Peeling of the product (CUT-Opening, COP) in the exit area of the extruder cooling nozzle, (c) device variant for multiple needle penetration (penetration-opening, POP) directly after the exit of the partially cooled product from the extruder cooling nozzle, (d) device variant for generating a secondary -Mixed flow (mix-opening, MOP) in the extruder cooling nozzle or (e) device variant for freeze structuring. Device for carrying out the method according to Claim 26 , characterized in that for (a) pore opening by rapid ambient pressure drop (flash opening, FOP) of the extrusion nozzle, a cutting device and a plastic conveyor belt partially perforated in the middle in sections are downstream of the cooling nozzle of an HMEC foaming extruder, as well as the conveyor belt with the cut-off part of the product lying on top is guided between two half-shells, which press against each other from above and below and enclose the conveyor belt and the product in a sealed manner, and these half-shells for the sudden application of a partial vacuum to the foamed extruded product via a vacuum line provided with a valve for quick opening with a vacuum accumulator and these are connected to a vacuum pump. Device for carrying out the method according to Claim 26 , characterized in that for (b) opening the pores by dividing or peeling the product (CUT-Opening, COP) in the extruder nozzle outlet, to ensure product strand guidance in the slot nozzle channel, cutting knives with a small blade width (≤ 2 mm) or thin cutting wires or water jet or laser Cutting devices are arranged in such a way that either (i) the surface layers are cut off (peeling off) with a layer thickness of ≦1 mm or (ii) the product strand is divided in the middle. Device for carrying out the method according to Claim 26 , characterized in that for (c) pore opening by multiple needle penetration (Penetration-Opening, POP) at the nozzle outlet, two rotatably suspended needle rollers equipped with solid needles with barbs (felt needles) or hollow needles with needle diameters between 0.3 - 5 mm are arranged, between which the strip-shaped extruded product is guided, and the needle penetration depth is set between 1-20 mm, depending on the product shape, and the puncture number density is set between 1-49 / cm ² . Device for carrying out the method according to Claim 26 , characterized in that for (d) pore opening by forced secondary mixed flow (Mix-Opening, MOP) according to the invention in the gap width between 10-100% of the slot channel height of the extrusion nozzle adjustable slot nozzle aperture (VSDA) in case (A) purely viscous Flow properties of the non- or partially solidified fluid system between 10-50% of the nozzle length before the nozzle end of the cooled extruder slot die, and in the case (B) viscoelastic flow properties of the non- or partially solidified fluid system between 5-95% of the nozzle length before the nozzle end of the cooled extruder slot die or is arranged directly at the end of the nozzle. Device according to claims 26 and 30 , characterized in that the (d) pore opening by forced secondary mixed flow (Mix-Opening, MOP) used in the slot width between 10-100% of the slot channel height of the extrusion nozzle Adjustable slot nozzle aperture (VSDA) in its 100% open condition corresponds exactly to the dimensions of the free extruder slot nozzle cross-section and, in the case of a flat, rectangular extruder nozzle slot channel, in the upper and lower wall delimiting the flow slot of the aperture device over the entire slot width, perpendicular to the direction of flow, a cut rotatable metal cylinder is sealingly embedded in each case with the gate surfaces of these cylinders being flush with the flow channel wall when the aperture is fully open, as well as an adjustable narrowing of the aperture on one side or symmetrically to the longitudinal axis of the nozzle when the cylinder is rotated externally by hand or by means of a servomotor r takes place, which corresponds to the maximum degree of closure of the slot channel at a twist angle of 90°. device after Claim 26 and 30 , characterized in that the (d) pore opening by forced secondary mixed flow (Mix-Opening, MOP) used in the slot width between 10-100% of the slot channel height of the extrusion nozzle Adjustable Slot Nozzle Aperture (VSDA) in its 100% open state exactly corresponds to the dimensions of the free cross-section of the extruder slot nozzle and in the case of an extruder nozzle with an annular gap for higher throughput rates, a piston-like ram with a conical attachment is arranged to narrow the annular slot gap in such a way that it is pushed in a defined axial manner, preferably by means of a servomotor, into the annular slot nozzle for adapting the extruder conically designed extruder outlet nozzle defines a defined narrowing of the annular slot gap. Device for carrying out the method according to claims 26 and 30-32, characterized in that for (d) pore opening by forced secondary mixed flow (mix opening, MOP), the extruder cooling nozzle and the extruder nozzle inlet are equipped according to the invention with 4-5 sensors (P1-P4, P5) for static pressure measurement, preferably one of the sensors (P1) flush with the wall in front of the extruder nozzle inlet and three of the sensors (P2-P4) in the extruder slot nozzle, two of which (P2, P3) flush with the wall in front of the slot channel constriction set using VSAD, and one (P4) also flush with the wall directly in the outlet flow of this narrowing of the slot duct, and in the case of viscoelastic fluid properties, an additional fifth sensor for static pressure measurement (P5) is placed directly opposite sensor P2 on the opposite side of the slot duct, but not flush with the wall but in a cavity (43) inserted in the bottom of the slot duct nozzle , and this cavity forms a cuboid bulge of the slot nozzle with in the direction of flow g oriented narrow rectangular cross-section, preferably in the dimension ranges (1-1.5) x (4-6) cm and a depth of 3-6 cm (s. 6 & 7 ). Device for carrying out the method according to claims 26 and 33 , characterized in that for (d) pore opening by forced secondary mixed flow (mix opening, MOP) by means of the static pressure sensors P1 to P3, the in-line detection of apparent extensional and shear viscosities in the nozzle inlet flow, by means of the static pressure sensors P2 and P5 a pressure difference proportional to the first normal stress difference N1 of the fluid system as an elastic parameter and by means the sensor P4 caused by the secondary mixing flow correlated with the intensity of this flow oscillatory pressure fluctuations can be measured. Device for carrying out the method according to Claim 26 , characterized in that for (e) opening the pores by means of freeze structuring, the extruder nozzle outlet is connected to a cooling immersion bath, in which the extrudate strand is rapidly cooled to below -20°C, preferably to below -50°C, and then at 1-2 hour intervals between two Cold storage devices is alternately rearranged, these devices being set to constant -1 and -20°C. use of the product claim 1 and one or more of the following claims 2 - 11 , characterized in that if vegetable proteins are used as the main component of the recipe, the resulting foamed product with a set degree of pore opening is used as a structured basic element for meat analogues and menus containing them, which are complemented by fluid sauces/juices/dressings/topping components bring about a gradual to complete filling of the open pores of the base element structured according to the invention. use of the product claim 1 and one or more of the following claims 2 - 11 , characterized in that if vegetable proteins are used as the main component of the recipe, the resulting foamed product with a set degree of pore opening is used as a structured basic element for meat analogues and menus containing such, which is used for complemented coatings and breadcrumbs applied in fluid or semi-fluid form by partial penetration into the open pores, improved adhesion to the surface of the base element and thus improved product stability. use of the product claim 1 and one or more of the following claims 2 - 11 , characterized in that in the case of using plant proteins as the recipe main component, which is based on appropriately adapted matrix masses, the resulting foamed product with a set degree of pore opening as a structured base element for cheese-like products, confectionery, baked goods, waffles / wafers and chocolate confectionery products , which, due to their ability to absorb fluid components in the open pores, can realize an advantageous embodiment of their sensory and/or nutritional properties.

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